JP3842893B2

JP3842893B2 - Electromagnetic relay and manufacturing method thereof

Info

Publication number: JP3842893B2
Application number: JP06122298A
Authority: JP
Inventors: 茂光青木; 明彦中村; 良夫岡本
Original assignee: Fujitsu Component Ltd
Current assignee: FCL Components Ltd
Priority date: 1997-07-28
Filing date: 1998-03-12
Publication date: 2006-11-08
Anticipated expiration: 2018-03-12
Also published as: JPH11102630A

Description

【０００１】
【発明の属する技術分野】
本発明は自動車等に搭載される車載用設備や音響用設備、パソコン等に組み込まれる低動作音型の電磁継電器に係り、特に安定した磁気吸引力を有し一層の小型化と製造コストの低減を可能にする電磁継電器に関する。
【０００２】
近年、電磁継電器の使用範囲が拡大され車載用設備を始めとして音響用設備やパソコン等にまで組み込まれているが、このような用途に供される電磁継電器は小型化と低コスト化とが可能であると共に消費電力の小さいことが要求される。
【０００３】
しかし、個別に形成された部品を組み立てる方式の従来の電磁継電器は各部品の小型化と低コスト化とに限界があり、また磁気回路等に各部品の寸法誤差に起因するばらつきがあると駆動マージン等が大きくなって消費電力の増大を招く。
【０００４】
そこで安定した磁気吸引力を有し一層の小型化と製造コストの低減を可能にする電磁継電器の開発が要望されている。
【０００５】
【従来の技術】
図７は従来の電磁継電器の主要部を示す斜視図、図８は従来の電磁継電器の駆動部を示す斜視図、図９は従来の駆動部の組立方法を示す側断面図である。
【０００６】
対象とする従来の電磁継電器は図７に示す如く駆動部１と２個の駆動部１が装着される固定接点ユニット３とを有し、固定接点ユニット３は通常の電磁継電器の内部基板と異なり空間を介し互いに対向するようベース４に装着されている。
【０００７】
駆動部１は図８に示す如くコイル端子11を具えたボビン12に巻回され両端部がコイル端子11に接続されたコイル13と、ボビン12を貫通する鉄心14およびボビン12の上方に添設され一端が鉄心14の先端に固着されたＬ字状の継鉄15を有する。
【０００８】
先端が継鉄15に嵌入する鉄心14は他端に頭頂部16を有し頭頂部16は組立時の位置合わせを無くすため通常は円形をなし、小型化された電磁継電器では磁気特性を向上させる手段として通常はヘッダー加工によって頭頂部が形成されている。
【０００９】
駆動部１はまた一端に固着された可動接点17を具え他端が継鉄15の背面に固着されたＬ字状の可動接点ばね18を有し、鉄心14の頭頂部16と継鉄15の開放端に対抗させた接極子19が可動接点ばね18の可動接点17を具えた側に固着されている。
【００１０】
Ｕ字ばね21を挟み片側にリード部22を具え他方に連結用接続片23を具えたリード端子24が可動接点ばね18に接続され、Ｕ字ばね21の他方に連結用接続片25、26を具えたリード端子27、28がボビン12上のコイル端子11にそれぞれ接続される。
【００１１】
リード端子24の連結用接続片23と可動接点ばね18とは継鉄15が有する突起30に嵌挿されて同時にかしめられると共に、電気的接続の向上を図る手段として重ねられた連結用接続片23と可動接点ばね18とがスポット溶接によって接続される。
【００１２】
リード端子27、28の連結用接続片25、26とコイル端子11とはボビン12のスリット29に一緒に圧入することで接続され、電気的接続の向上を図る手段として例えばボビン12に設けられた孔からレーザ光を照射することにより両者を溶接する。
【００１３】
２個の駆動部１が有するコイル端子11にそれぞれ１個のリード端子27を接続すると４個のリード端子27を必要とするが、本発明の電磁継電器では隣接する２個のコイル端子11が同一リード端子28が有する連結用接続片26に接続されている。
【００１４】
このように２個の駆動部１の隣接するコイル端子11を同一リード端子28が有する連結用接続片26に接続することで、リード端子数が減少しリード端子の占有空間が省略されて小型化の推進と部品コストの削減や組立弛緩の短縮に寄与する。
【００１５】
固定接点ユニット３は図７に示す如くコ字状に折り曲げられた２個の固定接点ばね31、32と内部基板33とを具えており、前記可動接点17を挟み対抗する少なくとも一対の固定接点34が固定接点ばね31、32の一辺にそれぞれ固着されている。
【００１６】
一方、駆動部１が装着される内部基板33は図示省略されているが駆動部１のボビン12に係合する保持機構を具えており、更に固定接点ばね31、32の両端に係合し固定接点ばね31、32を所定の位置に保持する保持溝35、36、37、38を有する。
【００１７】
即ち、コ字状に折り曲げられた２個の固定接点ばね31、32は両端が保持溝35、36、37、38に嵌挿されて位置決めされ、固定接点ばね31、32の固定接点34が固着された一辺と対向する一辺が例えば熱かしめ等により内部基板33に固定される。
【００１８】
Ｕ字ばね21を挟んで片側にリード部22を具え他方に連結用接続片41を具えたリード端子42と固定接点ばね31、32とは、固定接点ばね31、32の相対する一辺に挟まれた中間の辺に連結用接続片41をそれぞれかしめることによって接続される。
【００１９】
このように固定接点ユニット３を具えた電磁継電器は駆動部４が固定接点ユニット５に装着されて中間完成体となり、中間完成体の状態で全てのリード端子が所定の位置に装着されているため組立や中間における試験が極めて容易になる。
【００２０】
固定接点ユニット３が装着されるベース４にはリード端子のリード部を貫通させる複数の貫通孔43が形成されており、中間完成体の所定の位置に設けられた全てのリード端子を貫通孔43に嵌挿することにより電磁継電器の組立が完了する。
【００２１】
従来の電磁継電器における上記コイルボビン12と鉄心14とヨーク15との関係を図９に基づいて更に詳細に説明すると、鉄心14は先端に段差部10を有し段差部10がヨーク15に当接するまで鉄心14がヨーク15の貫通孔20に嵌挿され固着される。
【００２２】
一般に電磁継電器における磁気特性は鉄心14の頭頂部16とヨーク15の開放端端面の間に介在するギャップｔに依存し、特に駆動部のコイル消費電力はギャップｔのばらつきに対応し変動するため高精度なギャップｔを形成する必要がある。
【００２３】
そこで固着に際し組立治具８にコイルボビン12と鉄心14とヨーク15を載置して、鉄心14の頭頂部16とヨーク15の開放端の端面の間に所定のギャップｔを確保しながら、ポンチ９で鉄心14の先端を押し広げヨーク15を鉄心14に固着している。
【００２４】
一方、頭頂部16とヨーク15との間に挟まるコイルボビン12の全長は鉄心14の頭頂部16と段差部10との間より若干長く、ヨーク15が段差部10に当接するまで鉄心14をヨーク15の貫通孔20に嵌挿し固着することでコイルボビン12が圧縮される。
【００２５】
その結果、圧縮されたコイルボビン12の復元力に起因してコイルボビン12とヨーク15または鉄心14との間に摩擦が生じ、振動の発生や電磁継電器の短寿命化の要因となるコイルボビン12に嵌挿された鉄心14の回動を防止することができる。
【００２６】
【発明が解決しようとする課題】
しかし、鉄心が段差部を有し段差部がヨークに当接するまで鉄心がヨークの貫通孔に嵌挿される従来の電磁継電器は、鉄心やヨークの加工時の寸法誤差を吸収する手段がなくそれ等の誤差が集積されてギャップｔを変動させる要因になる。
【００２７】
また、圧縮されたコイルボビンの復元力に起因する摩擦によりコイルボビンに嵌挿された鉄心の回動を防止しているが、部品の寸法誤差等で復元力が過度になると鉄心とヨークとの平行度が阻害されてギャップｔを変動させる要因になる。
【００２８】
その結果、ギャップｔが所定の範囲から大きく外れた駆動部を所定の範囲に収めるために行う調整工程が必要になり、またギャップｔのばらつきに対応するためコイル消費電力に大きいマージンを見込む必要があるという問題があった。
【００２９】
本発明の目的は安定した磁気吸引力を有し一層の小型化と製造コストの低減を可能にする電磁継電器を提供することにある。
【００３０】
図１と図３は本発明になる電磁継電器の主要部を示す斜視図である。なお全図を通し
同じ対象物は同一記号で表している。
【００３１】
上記課題はコイル56が巻回されるコイルボビン51と、一端に頭頂部54を具えコイルボビン51を貫通する鉄心52と、鉄心52の他端に固着されるヨーク53とを有し、鉄心52は、コイルボビン51が成形される際にインサートされ、コイルボビン51と一体化されており、頭頂部 54 は、フランジ部 58 と、フランジ部 58 の一方の面から突出する磁極部 59 とを有し、フランジ部 58 は、外形が多角形または楕円形で磁極部 59 を有する側の面がコイルボビン 51 の端面と同一平面をなし、磁極部 59 は、外形がフランジ部 58 と同一形状または円形で、フランジ部 58 との間に段差を有する本発明の電磁継電器によって達成される。
【００３２】
このようにコイルボビンを成形する際に鉄心がインサートされ、コイルボビンと鉄心が一体化される本発明の電磁継電器は、鉄心の回動防止が不要になってコイルボビンとヨークの間に隙間を設けることが可能で、コイルボビンが圧縮されて生じる頭頂部とヨークの端面の間に介在するギャップｔの変動が防止される。
【００３３】
また、例えば鉄心がヨークの固着される領域の両側に、ヨークの固着領域と外径が等しい調整域を有することによって、ギャップｔを優先してヨークの固着位置を決めることが可能になってギャップｔのばらつきを抑制することができる。
【００３４】
ギャップｔのばらつきを抑制することによって本発明の電磁継電器は磁気特性、特にコイルの消費電力が安定化され、従来の製造工程において駆動部の組立後行われていたギャップｔの調整作業が大幅に軽減され製造コストが削減される。
【００３５】
更に、成形する際に鉄心と一体化することによってコイルボビンを薄肉化しても充分な強度を持たせることが可能で、しかも成形後に鉄心を挿入する場合と異なり鉄心との間の隙間が不要になってコイルボビンを小型化することができる。
【００３６】
即ち、安定した磁気吸引力を有し一層の小型化と製造コストの低減を可能にする電磁継電器を実現することができる。
【００３７】
【発明の実施の形態】
以下添付図により本発明の実施例について説明する。なお図２は本発明における駆動部の組立方法を示す側断面図、図３は本発明の別の実施例を示す斜視図、図４は別の実施例の作用を説明する側断面図、図５は本発明の更に別の実施例を示す斜視図、図６は更に別の実施例の作用を説明する側断面図である。
【００３８】
本発明になる電磁継電器は図１に示す如く駆動部５が一体化されたコイルボビン51および鉄心52とヨーク53とを有し、一端に頭頂部54を具えた鉄心52はコイルボビン51を成形する際にインサートされてコイルボビン51と一体化されている。
【００３９】
鉄心52はコイルボビン51を成形する際にインサートモールドされ強い外力が印加されなければ回動することはないが、衝撃等により回動可能になるのを防止するため頭頂部54を多角形または楕円形（図は長方形）にし回動不能にしている。
【００４０】
このように成形時に鉄心と一体化することによってコイルボビンを薄肉化しても充分な強度を持たせることが可能で、しかも成形後に鉄心を挿入する場合と異なり鉄心との間の隙間が不要になってコイルボビンを小型化することができる。
【００４１】
なお、コイルボビン51の筒状部に形成された切り欠き55はインサートモールド時に鉄心52を所定位置に保持するもので、図示の如くコイルボビン51にコイル56を巻回したときにコイル56の下に隠れ電磁継電器の特性を阻害することはない。
【００４２】
一方、Ｌ字状のヨーク53はコイルボビン51に添設され鉄心52の他端がヨーク53に設けられた貫通孔57に嵌挿されるが、図示の如く鉄心52の他端はストレートでヨーク53が固着される領域の両側にそれぞれ外径が等しい調整域を具えている。
【００４３】
鉄心52とヨーク53の固着は図２に示す如く一体化されたコイルボビン51および鉄心52を組立治具８の上に載置した後、貫通孔57を鉄心52に嵌挿して開放端端面が組立治具８に当接するまでヨーク53を押し込み所定のギャップｔを確保する。
【００４４】
鉄心52の頭頂部54とヨーク53の開放端端面を組立治具８に当接させたときコイルボビン51とヨーク53の間に隙間があり、ヨーク53の固着に際して所定のギャップｔの確保を優先して鉄心52上にヨーク53の固定領域を設定することができる。
【００４５】
ヨーク53の固定領域が設定されるとポンチ９を用いて鉄心52の先端が押し広げられヨーク53が鉄心52に固着されるが、鉄心52やヨーク53の製造工程において生じた寸法誤差は調整領域に吸収され所定のギャップｔを変動させることはない。
【００４６】
なお、本実施例ではポンチ９を用いて鉄心52の先端を押し広げることによってヨーク53を鉄心52の一端に固着しているが、例えばヨーク53の固定領域が設定された後でヨーク53と鉄心52の固着部にレーザを照射して両者を溶接してもよい。
【００４７】
また、前述の如くコイルボビン51とヨーク53の間に隙間がありヨーク53の固着時にコイルボビン51が圧縮されないため、コイルボビンの復元力によって鉄心52とヨーク53との平行度が阻害されて所定のギャップｔを変動させることはない。
【００４８】
このようにコイルボビンを成形する際に鉄心がインサートされ、コイルボビンと鉄心が一体化される本発明の電磁継電器は、鉄心の回動防止が不要になってコイルボビンとヨークの間に隙間を設けることが可能で、コイルボビンが圧縮されて生じる頭頂部とヨークの端面の間に介在するギャップｔの変動が防止される。
【００４９】
また、例えば鉄心がヨークの固着される領域の両側に、ヨークの固着領域と外径が等しい調整域を有することによって、ギャップｔを優先してヨークの固着位置を決めることが可能になってギャップｔのばらつきを抑制することができる。
【００５０】
ギャップｔのばらつきを抑制することによって本発明の電磁継電器は磁気特性、特にコイルの消費電力が安定化され、従来の製造工程において駆動部の組立後行われていたギャップｔの調整作業が大幅に軽減され製造コストが削減される。
【００５１】
更に、成形する際に鉄心と一体化することによってコイルボビンを薄肉化しても充分な強度を持たせることが可能で、しかも成形後に鉄心を挿入する場合と異なり鉄心との間の隙間が不要になってコイルボビンを小型化することができる。
【００５２】
因みに発明者等が試作した本発明になる電磁継電器は鉄心とコイルボビンとが一体化されているため自動組立が容易で、従来の電磁継電器と比較してコイルの消費電力が２５％減少し全体の体積が２５％小さくなることが確認されている。
【００５３】
即ち、安定した磁気吸引力を有し一層の小型化と製造コストの低減を可能にする電磁継電器を実現することができる。
しかし、前記実施例における鉄心52は樹脂で形成されたコイルボビン51から頭頂部54の一部が突出するよう形成され、コイルボビン51中にインサートする際に図４(b) に示す如く頭頂部54の一部をモールド金型７に嵌入させる必要がある。
【００５４】
このようにインサートに際して頭頂部54の一部を嵌入させるモールド金型７は頭頂部54との間に隙間が介在するため、コイルボビン51を成形する際に溶融した樹脂がモールド金型７と頭頂部54の間に流入しばり71を発生させる要因になる。
【００５５】
ばり71の発生はモールド金型７の加工精度を高めることで抑制されるがモールド金型７の製造コストが極めて高価で、しかもコイルボビン51の成形に伴い頭頂部54の装着を繰り返すことによって傷が付き寿命を短くするという問題がある。
【００５６】
そこで本発明の別の実施例は図３に示す如く鉄心52は一端にフランジ部58と磁極部59を有する頭頂部60を具えており、外形が多角形または楕円形のフランジ部58は磁極部59を有する側の面がコイルボビン51の端面と同一平面をなしている。
【００５７】
一方、フランジ部58より小さくコイルボビン51の端面と同一平面をなすフランジ部58の端面から突出する磁極部59は、フランジ部58と同一形状または円形をした外形を有しその端面とフランジ部58の端面との間には段差が形成されている。
【００５８】
このようにフランジ部58と磁極部59とを有する頭頂部60を具えた鉄心52はコイルボビン51にインサートするに際して、図４(a) に示す如くフランジ部58の端面がモールド金型７の端面に押し当てられてばりの発生を抑制することができる。
【００５９】
フランジ部58の端面がモールド金型７に当接するとフランジ部58から突出した磁極部59はモールド金型７に嵌入するが、磁極部59とモールド金型７との隙間は品質に関係なくモールド金型のコストを低減すると共に長寿命化を可能にする。
【００６０】
また、前記実施例における鉄心52はヨークを固着する側の外径が一様でその一部がコイルボビン51から突出しており、コイルボビン51中にインサートする際に図６(b) に示す如く鉄心52の一部をモールド金型７中に嵌入させる必要がある。
【００６１】
このようにインサートに際し鉄心52の一部を嵌入させる構造のモールド金型７は鉄心52との間に隙間が介在するため、コイルボビン51を成形する際に溶融した樹脂がモールド金型７と鉄心52との間に流入しばり72を発生させる要因になる。
【００６２】
ばり72の発生はモールド金型７の加工精度を高めることで抑制されるがモールド金型７の製造コストを高くすると共に、コイルボビンの成形時に鉄心の装着を繰り返すと嵌入部に傷が付きモールド金型の寿命を短くするという問題がある。
【００６３】
そこで本発明の更に別の実施例は図５に示す如く鉄心52のヨークを固着する側に形成された円形のフランジ61を有し、鉄心52にヨークが嵌挿されるとヨークと対向する側のフランジ61の面はコイルボビン51の端面と同一平面をなしている。
【００６４】
このようにヨークを固着する側に円形のフランジ61が形成された鉄心52はコイルボビン51にインサートするに際して、図６(a) に示す如くフランジ61の一方の面がモールド金型７の端面に当接するためばりの発生を抑制することができる。
【００６５】
フランジ61がモールド金型７の端面に当接すると鉄心52のフランジ61から突出した領域はモールド金型７に嵌入するが、鉄心の突出部とモールド金型の隙間は品質に関係なくモールド金型のコストを低減すると共に長寿命化を可能にする。
【００６６】
即ち、鉄心にフランジ部と磁極部とを有する頭頂部、またはヨークと対向する面を具えたフランジを設けることにより、本発明になる電磁継電器の品質を高めモールド金型のコスト低減と長寿命化の可能な電磁継電器を得ることができる。
【００６７】
【発明の効果】
上述の如く本発明によれば安定した磁気吸引力を有し、一層の小型化と製造コストの低減を可能にする電磁継電器を提供することができる。
【図面の簡単な説明】
【図１】本発明になる電磁継電器の主要部を示す斜視図である。
【図２】本発明における駆動部の組立方法を示す側断面図である。
【図３】本発明の別の実施例を示す斜視図である。
【図４】別の実施例の作用を説明する側断面図である。
【図５】本発明の更に別の実施例を示す斜視図である。
【図６】更に別の実施例の作用を説明する側断面図である。
【図７】従来の電磁継電器の主要部を示す斜視図である。
【図８】従来の電磁継電器の駆動部を示す斜視図である。
【図９】従来の駆動部の組立方法を示す側断面図である。
【符号の説明】
５駆動部７モールド金型
８組立治具９ポンチ
51 コイルボビン 52 鉄心
53 ヨーク 54、60 頭頂部
55 切り欠き 56 コイル
57 貫通孔 58 フランジ部
59 磁極部 61 フランジ
71、72 ばり[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a low operating sound type electromagnetic relay incorporated in an in-vehicle facility, an acoustic facility, a personal computer, etc. mounted on an automobile or the like, and particularly has a stable magnetic attraction force and further downsizing and reduction in manufacturing cost. It is related with the electromagnetic relay which makes possible.
[0002]
In recent years, the range of use of electromagnetic relays has been expanded and incorporated into in-vehicle equipment, acoustic equipment, personal computers, etc., but electromagnetic relays used for such applications can be reduced in size and cost. And low power consumption is required.
[0003]
However, conventional electromagnetic relays that assemble individually formed parts have limitations in reducing the size and cost of each part, and drive when there are variations in the magnetic circuit due to dimensional errors in each part. The margin and the like are increased, resulting in an increase in power consumption.
[0004]
Thus, there is a demand for the development of an electromagnetic relay that has a stable magnetic attractive force and can be further reduced in size and reduced in manufacturing cost.
[0005]
[Prior art]
FIG. 7 is a perspective view showing a main part of a conventional electromagnetic relay, FIG. 8 is a perspective view showing a driving part of the conventional electromagnetic relay, and FIG. 9 is a side sectional view showing an assembling method of the conventional driving part.
[0006]
The target conventional electromagnetic relay has a driving unit 1 and a fixed contact unit 3 to which two driving units 1 are mounted as shown in FIG. 7, and the fixed contact unit 3 is different from an internal substrate of a normal electromagnetic relay. The base 4 is mounted so as to face each other through the space.
[0007]
As shown in FIG. 8, the drive unit 1 is wound around a bobbin 12 having a coil terminal 11 and has both ends connected to the coil terminal 11, an iron core 14 passing through the bobbin 12, and a bobbin 12. The L-shaped yoke 15 is fixed to the tip of the iron core 14 at one end.
[0008]
The iron core 14 whose tip is inserted into the yoke 15 has a crown 16 at the other end, and the crown 16 is usually circular in order to eliminate alignment during assembly, and a miniaturized electromagnetic relay improves magnetic characteristics. As a means, the top of the head is usually formed by header processing.
[0009]
The drive unit 1 also has an L-shaped movable contact spring 18 having a movable contact 17 secured to one end and the other end secured to the back surface of the yoke 15, and the top 16 of the iron core 14 and the yoke 15. An armature 19 opposed to the open end is fixed to the side of the movable contact spring 18 having the movable contact 17.
[0010]
A lead terminal 24 having a lead 22 on one side with a U-shaped spring 21 and a connecting connection piece 23 on the other side is connected to the movable contact spring 18, and connecting connection pieces 25, 26 are connected to the other side of the U-shaped spring 21. The provided lead terminals 27 and 28 are connected to the coil terminals 11 on the bobbin 12, respectively.
[0011]
The connecting connection piece 23 of the lead terminal 24 and the movable contact spring 18 are simultaneously inserted into the protrusion 30 of the yoke 15 and caulked, and overlapped as a means for improving the electrical connection. And the movable contact spring 18 are connected by spot welding.
[0012]
The connecting connecting pieces 25 and 26 for connecting the lead terminals 27 and 28 and the coil terminal 11 are connected by press-fitting together into the slit 29 of the bobbin 12, and are provided, for example, on the bobbin 12 as means for improving electrical connection. Both are welded by irradiating a laser beam from the hole.
[0013]
When one lead terminal 27 is connected to each of the coil terminals 11 of the two drive units 1, four lead terminals 27 are required. However, in the electromagnetic relay of the present invention, two adjacent coil terminals 11 are the same. The lead terminal 28 is connected to the connecting connecting piece 26.
[0014]
By connecting the adjacent coil terminals 11 of the two drive units 1 to the connecting connecting piece 26 of the same lead terminal 28 in this way, the number of lead terminals is reduced and the space occupied by the lead terminals is omitted, thereby reducing the size. This contributes to the reduction of parts costs and assembly relaxation.
[0015]
The fixed contact unit 3 includes two fixed contact springs 31 and 32 bent in a U-shape as shown in FIG. 7 and an internal substrate 33, and at least a pair of fixed contacts 34 sandwiching the movable contact 17 therebetween. Are fixed to one side of the fixed contact springs 31 and 32, respectively.
[0016]
On the other hand, although not shown, the internal substrate 33 to which the drive unit 1 is mounted has a holding mechanism that engages with the bobbin 12 of the drive unit 1, and further engages and fixes both ends of the fixed contact springs 31 and 32. Holding grooves 35, 36, 37, and 38 for holding the contact springs 31 and 32 at predetermined positions are provided.
[0017]
That is, the two fixed contact springs 31 and 32 bent in a U-shape are positioned by being fitted into the holding grooves 35, 36, 37 and 38, and the fixed contact 34 of the fixed contact springs 31 and 32 is fixed. One side opposite to the one side is fixed to the internal substrate 33 by, for example, heat caulking.
[0018]
A lead terminal 42 having a lead portion 22 on one side and a connecting connecting piece 41 on the other side of the U-shaped spring 21 and the fixed contact springs 31 and 32 are sandwiched between opposite sides of the fixed contact springs 31 and 32. Connection is made by caulking the connecting connecting pieces 41 to the intermediate sides.
[0019]
As described above, the electromagnetic relay having the fixed contact unit 3 has the drive unit 4 mounted on the fixed contact unit 5 to be an intermediate completed body, and all lead terminals are mounted at predetermined positions in the state of the intermediate completed body. Assembly and intermediate tests are extremely easy.
[0020]
The base 4 to which the fixed contact unit 3 is attached is formed with a plurality of through holes 43 that penetrate the lead portions of the lead terminals, and all the lead terminals provided at predetermined positions of the intermediate finished product are passed through the through holes 43. The assembly of the electromagnetic relay is completed by being inserted into.
[0021]
The relationship among the coil bobbin 12, the iron core 14 and the yoke 15 in the conventional electromagnetic relay will be described in more detail with reference to FIG. 9. The iron core 14 has a stepped portion 10 at the tip until the stepped portion 10 contacts the yoke 15. The iron core 14 is fitted and fixed in the through hole 20 of the yoke 15.
[0022]
In general, the magnetic characteristics of an electromagnetic relay depend on the gap t interposed between the top 16 of the iron core 14 and the open end face of the yoke 15, and the coil power consumption of the driving unit varies particularly in response to variations in the gap t. It is necessary to form an accurate gap t.
[0023]
Therefore, the coil bobbin 12, the iron core 14, and the yoke 15 are placed on the assembling jig 8 at the time of fixing, and the punch 9 is secured while ensuring a predetermined gap t between the top 16 of the iron core 14 and the open end face of the yoke 15. Then, the tip of the iron core 14 is pushed and the yoke 15 is fixed to the iron core 14.
[0024]
On the other hand, the total length of the coil bobbin 12 sandwiched between the top 16 and the yoke 15 is slightly longer than between the top 16 and the step 10 of the iron core 14, and the iron core 14 is moved to the yoke 15 until the yoke 15 contacts the step 10. The coil bobbin 12 is compressed by being inserted into and secured to the through hole 20.
[0025]
As a result, friction is generated between the coil bobbin 12 and the yoke 15 or the iron core 14 due to the restoring force of the compressed coil bobbin 12, and the coil bobbin 12 is inserted into the coil bobbin 12, which causes generation of vibration and shortening of the life of the electromagnetic relay. The rotation of the iron core 14 can be prevented.
[0026]
[Problems to be solved by the invention]
However, the conventional electromagnetic relay in which the iron core has a stepped portion and the iron core is inserted into the through-hole of the yoke until the stepped portion comes into contact with the yoke has no means for absorbing dimensional errors when processing the iron core or the yoke. Are accumulated to cause the gap t to fluctuate.
[0027]
In addition, the friction caused by the restoring force of the compressed coil bobbin prevents rotation of the iron core inserted into the coil bobbin. However, if the restoring force becomes excessive due to dimensional error of parts, the parallelism between the iron core and the yoke Becomes a factor that fluctuates the gap t.
[0028]
As a result, it is necessary to perform an adjustment process for keeping the drive unit in which the gap t is greatly deviated from the predetermined range within the predetermined range, and it is necessary to allow for a large margin in the coil power consumption in order to cope with the variation in the gap t. There was a problem that there was.
[0029]
An object of the present invention is to provide an electromagnetic relay that has a stable magnetic attractive force and enables further miniaturization and reduction in manufacturing cost.
[0030]
1 and 3 are perspective views showing the main part of an electromagnetic relay according to the present invention. Throughout the drawings, the same object is represented by the same symbol.
[0031]
The above-described problem includes a coil bobbin 51 around which a coil 56 is wound, an iron core 52 having a top 54 at one end and penetrating the coil bobbin 51, and a yoke 53 fixed to the other end of the iron core 52. is inserted in the coil bobbin 51 is molded, which is integrated with the coil bobbin 51, the top portion 54 has a flange portion 58, and a magnetic pole portion 59 projecting from one surface of the flange portion 58, the flange portion 58, outer shape without surface on the side having a magnetic pole portion 59 in polygonal or elliptical end faces flush with the coil bobbin 51, pole portion 59, the outer shape is the same shape or circular and the flange portion 58, the flange portion 58 This is achieved by the electromagnetic relay of the present invention having a step between the two .
[0032]
Thus, the electromagnetic relay of the present invention in which the iron core is inserted when the coil bobbin is formed and the coil bobbin and the iron core are integrated can eliminate the need to prevent the iron core from rotating, and can provide a gap between the coil bobbin and the yoke. It is possible to prevent the fluctuation of the gap t interposed between the top of the head and the end face of the yoke, which is caused by compressing the coil bobbin.
[0033]
In addition, for example, by providing an adjustment area on the both sides of the area where the iron core is fixed to the yoke, the outer diameter is equal to that of the fixed area of the yoke, it is possible to determine the fixing position of the yoke giving priority to the gap t. Variations in t can be suppressed.
[0034]
By suppressing the variation of the gap t, the electromagnetic relay of the present invention stabilizes the magnetic characteristics, particularly the power consumption of the coil, and the adjustment work of the gap t, which has been performed after the assembly of the drive unit in the conventional manufacturing process, is greatly increased. This reduces manufacturing costs.
[0035]
Furthermore, it is possible to provide sufficient strength even if the coil bobbin is thinned by integrating it with the iron core during molding, and unlike the case where the iron core is inserted after molding, there is no need for a gap between the iron core and the core. Thus, the coil bobbin can be reduced in size.
[0036]
That is, it is possible to realize an electromagnetic relay that has a stable magnetic attractive force and enables further miniaturization and reduction of manufacturing cost.
[0037]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the accompanying drawings. 2 is a side sectional view showing a method of assembling the drive unit in the present invention, FIG. 3 is a perspective view showing another embodiment of the present invention, and FIG. 4 is a side sectional view for explaining the operation of the other embodiment. 5 is a perspective view showing still another embodiment of the present invention, and FIG. 6 is a side sectional view for explaining the operation of still another embodiment.
[0038]
As shown in FIG. 1, the electromagnetic relay according to the present invention has a coil bobbin 51, an iron core 52, and a yoke 53, in which the drive unit 5 is integrated, and the iron core 52 having a top 54 at one end is formed when the coil bobbin 51 is formed. And is integrated with the coil bobbin 51.
[0039]
The iron core 52 is insert-molded when the coil bobbin 51 is molded and does not rotate unless a strong external force is applied, but the top 54 is polygonal or elliptical to prevent it from being able to rotate due to impact or the like. (The figure is a rectangle).
[0040]
In this way, by integrating with the iron core at the time of molding, it is possible to give sufficient strength even if the coil bobbin is thinned, and unlike the case where the iron core is inserted after molding, there is no need for a gap between the iron core and the core. The coil bobbin can be reduced in size.
[0041]
The notch 55 formed in the cylindrical part of the coil bobbin 51 holds the iron core 52 in a predetermined position during insert molding, and is hidden under the coil 56 when the coil 56 is wound around the coil bobbin 51 as shown in the figure. It does not interfere with the characteristics of the electromagnetic relay.
[0042]
On the other hand, the L-shaped yoke 53 is attached to the coil bobbin 51, and the other end of the iron core 52 is inserted into a through hole 57 provided in the yoke 53, but the other end of the iron core 52 is straight and the yoke 53 is not shown in the figure. Adjustment areas having the same outer diameter are provided on both sides of the area to be fixed.
[0043]
As shown in FIG. 2, the iron bobbin 51 and the iron core 52 are mounted on the assembly jig 8, and then the through hole 57 is inserted into the iron core 52 to assemble the open end face. The yoke 53 is pushed in until it comes into contact with the jig 8, and a predetermined gap t is secured.
[0044]
There is a gap between the coil bobbin 51 and the yoke 53 when the top end portion 54 of the iron core 52 and the open end surface of the yoke 53 are brought into contact with the assembly jig 8, and priority is given to securing a predetermined gap t when the yoke 53 is fixed. Thus, a fixed region of the yoke 53 can be set on the iron core 52.
[0045]
When the fixed region of the yoke 53 is set, the tip of the iron core 52 is pushed and widened by using the punch 9 and the yoke 53 is fixed to the iron core 52. However, the dimensional error generated in the manufacturing process of the iron core 52 and the yoke 53 is an adjustment region. And the predetermined gap t is not changed.
[0046]
In this embodiment, the yoke 53 is fixed to one end of the iron core 52 by using the punch 9 to push the tip of the iron core 52 wide. For example, after the fixing region of the yoke 53 is set, the yoke 53 and the iron core are fixed. The 52 fixing portions may be irradiated with laser to weld them together.
[0047]
Further, as described above, there is a gap between the coil bobbin 51 and the yoke 53, and the coil bobbin 51 is not compressed when the yoke 53 is fixed. Therefore, the parallelism between the iron core 52 and the yoke 53 is hindered by the restoring force of the coil bobbin, and a predetermined gap t Does not fluctuate.
[0048]
Thus, the electromagnetic relay of the present invention in which the iron core is inserted when the coil bobbin is formed and the coil bobbin and the iron core are integrated can eliminate the need to prevent the iron core from rotating, and can provide a gap between the coil bobbin and the yoke. It is possible to prevent the fluctuation of the gap t interposed between the top of the head and the end face of the yoke, which is caused by compressing the coil bobbin.
[0049]
In addition, for example, by providing an adjustment area on the both sides of the area where the iron core is fixed to the yoke, the outer diameter is equal to that of the fixed area of the yoke, it is possible to determine the fixing position of the yoke giving priority to the gap t. Variations in t can be suppressed.
[0050]
By suppressing the variation of the gap t, the electromagnetic relay of the present invention stabilizes the magnetic characteristics, particularly the power consumption of the coil, and the adjustment work of the gap t, which has been performed after the assembly of the drive unit in the conventional manufacturing process, is greatly increased. This reduces manufacturing costs.
[0051]
Furthermore, it is possible to provide sufficient strength even if the coil bobbin is thinned by integrating it with the iron core during molding, and unlike the case where the iron core is inserted after molding, there is no need for a gap between the iron core and the core. Thus, the coil bobbin can be reduced in size.
[0052]
By the way, the electromagnetic relay according to the present invention, which was experimentally produced by the inventors, is easy to assemble automatically because the iron core and the coil bobbin are integrated. The power consumption of the coil is reduced by 25% compared to the conventional electromagnetic relay, and the whole It has been confirmed that the volume is reduced by 25%.
[0053]
That is, it is possible to realize an electromagnetic relay that has a stable magnetic attractive force and can be further reduced in size and reduced in manufacturing cost.
However, the iron core 52 in the above-described embodiment is formed so that a part of the crown 54 protrudes from the coil bobbin 51 made of resin, and when inserted into the coil bobbin 51, as shown in FIG. A part needs to be fitted into the mold 7.
[0054]
As described above, since a gap is interposed between the mold die 7 for inserting a part of the crown 54 at the time of insertion and the crown 54, the resin melted when the coil bobbin 51 is molded is molded into the mold die 7 and the crown. It becomes a factor which generates the flow-in flash 71 during 54.
[0055]
The occurrence of the flash 71 is suppressed by increasing the processing accuracy of the mold 7, but the manufacturing cost of the mold 7 is extremely high, and the scratches are caused by repeated mounting of the top 54 as the coil bobbin 51 is formed. There is a problem of shortening the service life.
[0056]
Therefore, in another embodiment of the present invention, as shown in FIG. 3, an iron core 52 has a top 60 having a flange 58 and a magnetic pole 59 at one end, and the flange 58 having a polygonal or elliptical outer shape is a magnetic pole. The surface having 59 is flush with the end surface of the coil bobbin 51.
[0057]
On the other hand, the magnetic pole portion 59 that protrudes from the end surface of the flange portion 58 that is smaller than the flange portion 58 and is flush with the end surface of the coil bobbin 51 has the same shape as the flange portion 58 or a circular outer shape. A step is formed between the end faces.
[0058]
When the iron core 52 having the top 60 having the flange 58 and the magnetic pole 59 as described above is inserted into the coil bobbin 51, the end face of the flange 58 becomes the end face of the mold 7 as shown in FIG. The generation of flash can be suppressed by being pressed.
[0059]
When the end surface of the flange portion 58 comes into contact with the mold die 7, the magnetic pole portion 59 protruding from the flange portion 58 is fitted into the mold die 7. However, the gap between the magnetic pole portion 59 and the mold die 7 is a mold regardless of the quality. It reduces the cost of molds and enables longer life.
[0060]
Further, the iron core 52 in the above embodiment has a uniform outer diameter on the side to which the yoke is fixed, and a part of the iron core 52 protrudes from the coil bobbin 51. When the iron core 52 is inserted into the coil bobbin 51, as shown in FIG. It is necessary to fit a part of the mold into the mold 7.
[0061]
Since the mold die 7 having a structure in which a part of the iron core 52 is inserted in the insert as described above has a gap between the iron core 52 and the mold, the resin melted when the coil bobbin 51 is formed is injected into the mold die 7 and the iron core 52. It becomes the factor which generates the flow-in flash 72 between the two.
[0062]
The occurrence of the flash 72 is suppressed by increasing the processing accuracy of the mold 7, but the manufacturing cost of the mold 7 is increased, and if the mounting of the iron core is repeated at the time of forming the coil bobbin, the fitting portion may be damaged. There is a problem of shortening the life of the mold.
[0063]
Therefore, another embodiment of the present invention has a circular flange 61 formed on the side of the iron core 52 to which the yoke is fixed, as shown in FIG. The surface of the flange 61 is flush with the end surface of the coil bobbin 51.
[0064]
When the iron core 52 having the circular flange 61 formed on the side to which the yoke is fixed is inserted into the coil bobbin 51, one surface of the flange 61 contacts the end surface of the mold 7 as shown in FIG. Generation of flash can be suppressed because of contact.
[0065]
When the flange 61 comes into contact with the end surface of the mold 7, the region protruding from the flange 61 of the iron core 52 is inserted into the mold 7, but the gap between the iron core protrusion and the mold is not affected by the quality of the mold. This makes it possible to reduce the cost and extend the service life.
[0066]
That is, by providing the top of the iron core with a flange portion and a magnetic pole portion, or a flange having a surface facing the yoke, the quality of the electromagnetic relay according to the present invention is improved and the cost and life of the mold are reduced. Possible electromagnetic relays can be obtained.
[0067]
【The invention's effect】
As described above, according to the present invention, it is possible to provide an electromagnetic relay that has a stable magnetic attractive force and can be further miniaturized and reduced in manufacturing cost.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a main part of an electromagnetic relay according to the present invention.
FIG. 2 is a side sectional view showing a method of assembling a drive unit in the present invention.
FIG. 3 is a perspective view showing another embodiment of the present invention.
FIG. 4 is a side sectional view for explaining the operation of another embodiment.
FIG. 5 is a perspective view showing still another embodiment of the present invention.
FIG. 6 is a side sectional view for explaining the operation of still another embodiment.
FIG. 7 is a perspective view showing a main part of a conventional electromagnetic relay.
FIG. 8 is a perspective view illustrating a driving unit of a conventional electromagnetic relay.
FIG. 9 is a side sectional view showing a conventional method of assembling a drive unit.
[Explanation of symbols]
5 Driving part 7 Mold die 8 Assembly jig 9 Punch
51 Coil bobbin 52 Iron core
53 York 54, 60 Top of head
55 Notch 56 Coil
57 Through hole 58 Flange
59 Magnetic pole 61 Flange
71, 72 burr

Claims

A coil bobbin around which a coil is wound, an iron core having a top at one end and penetrating the coil bobbin, and a yoke fixed to the other end of the iron core,
The iron core is inserted when the coil bobbin is molded, and is integrated with the coil bobbin .
The top portion has a flange portion and a magnetic pole portion protruding from one surface of the flange portion,
The flange portion has a polygonal or elliptical outer shape, and the surface on the side having the magnetic pole portion is flush with the end surface of the coil bobbin.
The electromagnetic relay according to claim 1 , wherein the magnetic pole portion has the same outer shape or a circular shape as the flange portion and has a step between the flange portion and the magnetic pole portion .

A method of manufacturing an electromagnetic relay having a coil bobbin around which a coil is wound, an iron core having a crown at one end and penetrating the coil bobbin, and a yoke fixed to the other end of the iron core, the crown being A flange portion and a magnetic pole portion protruding from one surface of the flange portion, and the flange portion has a polygonal or elliptical outer shape, and a surface on the side having the magnetic pole portion is flush with an end surface of the coil bobbin The magnetic pole part has the same outer shape or circular shape as the flange part, and has a step between the flange part,
  A mold forming step of forming the coil bobbin by inserting the iron core into the coil bobbin and pressing the flange portion against an end surface of the mold;
  A winding step of winding the coil around the coil bobbin integrated with the iron core;
  A yoke mounting step for inserting and fixing the yoke to the iron core.
  A method for manufacturing an electromagnetic relay.